Carton gluing machine and method

ABSTRACT

A novel carton forming apparatus has a travel path along which carton members move in rapid, continuous succession, when the machine is in operation. During such movement, intermittently movable means fold an entire longitudinal wall portion of the blank inwardly at substantially one time; means is also provided to effect contact between the wall portion so folded and a cooperating portion, in such a manner that substantially all of an area that has been rendered adhesive thereon is contacted and bonded at the same time. Novel feed mechanisms provide carton blanks in rapid succession to transport means of the machine, and novel folding mandrels and/or stationary mandrel elements may be used to effect the folding of the blanks. The invention also provides a method whereby cartons having a desirably rectilinear configuration can be formed at high production rates.

United States Patent [1 1 Palmer et al.

METHOD Filed:

Assignee:

CARTON GLUING MACHINE AND- Inventors: Charles E. Palmer; Stanley A.

Peters, Somers, both of Conn.

Palmer Machinery Development Appl. No.: 195,599

Related US. Application Data Continuation-impart of Ser. No. 26,653, April 8,

1973, abandoned.

US. Cl ..93/49 M, 93/36 M, 93/36 MM,

Int. Cl. ..B3lb 1/56, B3 lb 1/62, B3lb 49/02 Field of Search ..93/36 M, 36 MM, 36.3,

References Cited UNITED STATES PATENTS 11 3,733,986 51 May 22, 1973 3,379,102 4/1968 James ..93/36 MM 3,529,516 9/1970 Dorsey.... ..93/49 M 3,391,616 7/1968 Junco ..93/36 SQ Primary ExaminerAndrew R. Juhasz Assistant Examiner-Leon Gilden Attorney-Peter L. Costas [57] ABSTRACT A novel carton forming apparatus has a travel path along which carton members move in rapid, continuous succession, when the machine is in operation. During such movement, intermittently movable means fold an entire longitudinal wall portion of the blank inwardly at substantially one time; means is also provided to effect contact between the wall portion so folded and a cooperating portion, in such a manner that substantially all of an area that has been rendered adhesive thereon is contacted and bonded at the same time. Novel feed mechanisms provide carton blanks in rapid succession to transport means of the machine, and novel folding mandrels and/or stationary mandrel elements may be used to effect the folding of the blanks. The invention also provides a method whereby cartons having a desirably rectilinear configuration can be formed at high production rates.

18 Claims, 35 Drawing Figures PATENTED W 2 2 5 SHEET 7 or 8 PATENTEBHAYZZ 197a SHEET 8 OF 8 INVENTORS CHARLES EPALMER, STANLEY APETERS BY fmrfaw ATTORNEY CROSS REFERENCE TO RELATED APPLICATION The present application is a continuation in part of application Ser. No. 26,653, filed Apr. 8, 1970 and now abandoned.

BACKGROUND OF THE INVENTION Many types of apparatus have been devised in an effort to produce finished cartons from suitable blanks on a commercially practicable basis. Plowing or rolling devices are commonly relied upon to effect folding and to place wall flaps into position for bonding. Since these plowing or rolling devices operate to fold the flap progressively rather than simultaneously along the entire fold line, the leading edge of the flap reaches its ultimate position somewhat sooner than does the trailing edge thereof, often resulting in folds that deviate from the intended line.

Moreover, it is highly desirable to utilize very quick setting types of adhesives in manufacturing such cartons so as to obtain the maximum level of productivity; however, because the plowing devices of the type referred to create initial contact of the flap before the two cooperating wall portions are fully aligned in a square (i.e., rectilinear or parallel relationship), the use of such adhesives entails undesirable consequences. Thus, after initial contact, realignment of the glue flap to a more desirable position is not feasible, as a result of which it is necessary either that somewhat out-of-square cartons be tolerated or that slower setting adhesives be used so that the flap can be subsequently realigned; this, of course, slows the manufacturing process and is therefore undesirable. In addition to the foregoing, most of the apparatus presently available for carton folding and gluing tends to be unduly large and/or too slow for most efficient operation. Furthermore, in many cases the prior art does not operate on a continuous basis, and so does not offer the highest level of operational efficiency.

Accordingly, it is an object of the present invention to provide a carton forming apparatus wherein flaps or wall portions of the carton blank are folded along the entire length of the ultimate fold line substantially simultaneously to provide fold lines and wall portions that are parallel with respect to other portions of the blank.

It is also an object of the invention to provide such an apparatus wherein contact of surfaces to be bonded is effected simultaneously over substantially the entire adherent area thereof so that proper alignment is attained.

Another object is to provide a relatively small apparatus of this type which operates rapidly and substantially continuously to provide a high level of carton productivity.

Still another object of the invention is to provide a method wherein a multiplicity of cartons can be formed from blanks in rapid succession, and wherein such cartons have the wall portions thereof properly aligned and bonded in the desired rectilinear cross sectional configuration.

A further object is to provide such a method wherein a quick-setting adhesive may be employed to bond the wall portions of each blank to one another in proper alignment upon initial contact.

SUMMARY OF THE INVENTION It has now been found that the foregoing and related objects can be readily attained in a carton forming apparatus comprising a support providing a travel path for carton members, a folding mandrel having a folding surface, and means for intermittently moving the folding mandrel toward the travel path. The mandrel moves into a position with its folding surface effectively parallel to the path for engagement with a wall portion of a carton blank during its travel therealong, and the folding surface contacts the wall portion to simultaneously move the entire length thereof inwardly and to produce the entire length of the fold therein at one time. The machine also includes means along the travel path for rendering adherent an area of a surface of either the wall portion or of a cooperating portion of the carton blank that is to be bonded thereto. A bonding member has an engagement surface for effecting contact between the wall portion and the cooperating portion of the carton blank, and means is provided to support the bonding member in a position along the travel path downstream of the adherent-rendering means. The support means moves the bonding member intermittently inwardly toward the path to effect the contact between the wall and cooperating portions over substantially the entire adherent area thereof at the same time, to effect simultaneous bonding thereat. Transport means continuously moves a multiplicity of carton members in rapid succession along the travel path, and automatic means drives the transport means and operates the intermittently moving means and the bonding member support means in timed sequence.

The support of the apparatus desirably provides a travel surface adjacent the beginning of the travel path, and may additionally include a feed mechanism for the carton blanks. The feed mechanism comprises a magazine for supporting a stack of carton blanks at an acute angle relative to the travel surface, and so that the trailing edge of the bottommost carton blank rests thereupon. Means is provided for gripping and pivoting the bottommost carton blank about its trailing edge to an initial position along the travel path with the magazine permitting the gripping means to remove the carton blanks singly therefrom; the gripping means thereupon releases the blank.

The gripping means may comprise an intermittently evacuable cup having its open end adjacent the magazine, means for intermittently moving the cup into contact with the bottommost carton blank, and means for evacuating the cup to engage a blank thereupon. Preferably, the feed mechanism additionally includes delivery means comprising a driven transport roller positioned with its circumferential surface projecting upwardly into the plane of the travel surface of the support. In such a case, a pressure roller may be movable to a position over the released carton blank to press it against the circumferential surface of the transport roller, and thereby to carry the carton blank from the initial position to the transport means. Alternatively, the delivery means may comprise a pair of adjacent driven rollers having their axes aligned generally perpendicularly to the travel path to provide a nip therebetween that also extends generally perpendicularly to the path. The pair of rollers is mounted by suitable means for intermittent reciprocal movement toward the magazine to a position wherein the released blank is gripped in the nip therebetween, and away from the magazine to deliver the blank to the transport means.

Preferably, the apparatus includes at least a second folding mandrel of the type previously described to provide a pair thereof, with the folding surfaces of the mandrels being spaced transversely on opposite sides of the travel path. The mandrels are simultaneously movable by the intermittent moving means toward the travel path to contact, with the folding surfaces, portions along opposite sides of the carton blank and to produce the entire lengths of the folds therein at one time. The apparatus may include at least a second pair of folding mandrels spaced along the travel path, from the first-mentioned pair thereof, and each folding mandrel of the first-mentioned pair may move inwardly only to an intermediate position toward the path to partially fold the wall portion of the carton blank that is engaged thereby. One of the second pair of folding mandrels is movable, in such a case, inwardly toward the path from the plane of each of the intermediate positions to further fold the same wall portions that were engaged by the first-mentioned pair of folding man drels.

Most desirably, the folding surface provided on the folding mandrel is substantially equal in length to the wall portion of the carton blank that is to be engaged thereby. In such an instance, the apparatus may also include a relatively narrow stationary mandrel element that is generally transversely aligned with the folding surface and is mounted inwardly of the travel path and above the upper plane thereof, to permit the blank to pass therebetween with portions thereof extending outwardly of the stationary mandrel element. The folding mandrel is mounted on the intermittent moving means for movement from a position that is downward and outward of the stationary mandrel element to a position that is upward and inward thereof. Movement of the folding mandrel to the upward and inward position folds the wall portion of the carton blank that extends outwardly of the stationary mandrel element at least partially thereabout. The folding surface of the folding mandrel may be provided by an inwardly projecting elongated ridge that extends parallel to the travel path and cooperates with the remainder of the folding mandrel to form an upper shoulder thereabove and a lower shoulder therebelow, so that the carton blank may ride within the upper shoulder with the folding mandrel in the downward and outward position thereof. The underside of the ridge may bear against the carton blank wall portion and force it about the stationary mandrel element in the upward and inward position of the folding mandrel. The stationary mandrel element may have a groove formed therein that extends along the travel path and, in such an instance, the apparatus additionally includes a ram mechanism that has an element that is reciprocally movable perpendicularly to the path into and from the groove. The element of the ram mechanism is so configured and positioned as to simultaneously contact substantially the entire length of a wall portion of the carton blank to fold it about the stationary mandrel element and into the groove to form the entire length of the fold therein at one time. The means in the machine for rendering the surface area of the carton blank adherent may most desirably be a hot melt adhesive dispenser.

It has also been found that certain objects of the invention are attained in a method of forming cartons wherein a multiplicity of carton blanks are continuously moved in rapid succession along a travel path, during which movement each of the blanks is engaged at a wall portion defined by a line extending parallel to the travel path and over substantially its entire length. The entire wall portion is thereby folded inwardly toward the path along the parallel-extending line at substantially the same time. An area of a surface of either the wall portion or of a cooperating portion of the carton blank to be bonded thereto is rendered adherent and this may desirably be by the application of an adhesive thereto. During movement of the carton blank along the path contact is effected between the wall and cooperating portions of each carton blank over substantially the entire adherent area thereof at the same time to effect simultaneous bonding thereat.

Preferably, each of the blanks is engaged over substantially the entire length of wall portions at opposite sides thereof defined by a pair of lines extending parallel to the travel path, to simultaneously fold the wall portions in their entirety inwardly toward the path. As an additional step of the method, a rapid succession of carton blanks may automatically be fed to the travel path, during movement of which, subsequent to the engaging step and prior to the contact step, each of the blanks is most desirably engaged over substantially the entire length of second wall portions, defined by a second pair of lines extending parallel to the path along the opposite sides of each blank inwardly of the firstmentioned pair of lines. The entire second wall portions are folded inwardly toward the path at substantially the same time, and in one embodiment, the step of engaging and folding the first-mentioned wall portions may be effected in two successive stages. Most desirably, the method includes an automatic feeding step wherein the carton blanks are carried forward at a speed that equals the total of the linear speeds of two motion-producing effects, and a hot melt adhesive may be employed to render the surface area of the wall portion of the blank adherent, if so desired.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevational view of a carton forming apparatus embodying the present invention, with portions thereof being fragmentarily and/or schematically illustrated;

FIG. 2 is a plan view of the apparatus of FIG. 1;

FIG. 3 is a perspective view of a carton blank utilized in the apparatus, drawn to a greatly enlarged scale;

FIG. 4 is a perspective view of a carton formed from the blank of FIG. 3;

FIG. 5 is a side elevational view of the feed mechanism isolated from the rest of the apparatus, with portions thereof fragmentarily and schematically illustrated;

FIGS. 6A 6C are vertical section views along line 6-6 of FIG. 7, drawn to an enlarged scale and illustrating operation of the first flap-folding station of the apparatus;

FIG. 7 is a side elevational view, to an enlarged scale, of the folding assembly and actuating mechanism utilized at the first flap-folding station;

FIG. 8 is a vertical sectional view along line 8-8 in FIG. 1, drawn to an enlarged scale and illustrating the adhesive application station thereof;

FIGS. 9A and 9B are vertical sectional line 9-9 views along of FIG. 1, drawn to an enlarged scale and illustrating operations effected at the front and back wall folding station;

FIG. is a fragmentary perspective view of the mandrel employed in the apparatus, drawn to a greatly enlarged scale;

FIG. 11 is a vertical sectional view along line 11-11 in FIG. 1, drawn toan enlarged scale and illustrating the bond-securing station thereof;

FIGS. 12A and 12B are vertical sectional views along line l212 in FIG. 1, drawn to an enlarged scale and illustrating the operation of the preliminary carton collapsing station of the apparatus;

FIG. 13 is a vertical sectional view along line 13-13 of FIG. 1, drawn to an enlarged scale and illustrating the flattening mechanism;

FIGS. 14A 14F are perspective views of a carton blank, the carton produced therefrom, and of the blank in the intermediate stages of production, drawn to a greatly enlarged scale;

FIG. 15 is a fragmentary side elevational view of a portion of a second embodiment of apparatus of the present invention;

FIG. 16 is a plan view of the apparatus of FIG. 15;

FIGS. 17 17C are perspective views of a carton blank, the carton produced therefrom, and the blank at an intermediate stage of production, drawn to a greatly enlarged scale;

FIGS. 18A 18B are vertical sectional views taken at sequential locations along the length of the portion of the apparatus illustrated in FIGS. 15 and 16.

FIG. 19 is a fragmentary side elevational view of a flap contacting mechanism with an intermittently movable pressure plate; and

FIG. 20 is a fragmentary end elevational view of a rotary folding mechanism providing a flap folding station of the apparatus.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS First Embodiment Turning now in detail to the first 14 figures of the appended drawings, FIGS. 1 and 2 illustrate a carton forming and gluing apparatus embodying the present invention, FIG. 3 illustrates a carton blank suitably employed therein in its initial planar condition, and FIG. 4 shows the blank folded into a carton; the blank and carton are generally designated by the numerals l0 and 12, respectively. The blank 10 has a multiplicity of Iongitudinal pre-fold impressions or score lines 14 which facilitate its formation into the generally tubular configuration of the carton l2, and the lines 14 define edge flaps 11, front and back walls 13, and a sidewall 15 each of which may generically be referred to as a wall portion of the carton blank 10. A plurality of transverse score lines 16 are also formed in the blank 10 to facilitate folding of the flaps l8 defined thereby inwardly, to close the carton 12 in a conventional manner. The blank 10 also has a 'window 20 adjacent one end covered with a transparent material to permit viewing of the contents of the closed carton 12.

With particular reference to FIG; 5, a stack of carton blanks 10 is supported in a magazine 22 above the feed mechanism and horizontal table 27 adjacent the beginning of the travel path of the apparatus. The magazine 22 has inwardly stepped side plates-24 (only one of which is visible) at the lower edges of the sidewalls thereof, which retain the blanks 10 therein; it also has a toothed blade 26 at the front edge thereof, which primarily serves an anti-blocking function, ensuring that the blanks 10 are removed singly from the magazine 22 as required. The magazine 22 is tilted at an acute angle with respect to the table 27, and it is situated so that the trailing edge of the bottommost carton therein rests thereupon.

The feed mechanism includes a pair of side-by-side vacuum cups 28 (only one of which is seen in FIG. 5) rigidly affixed to a vacuum valve 30 by intermediate elbow ducts 32 and vacuum chambers 33. The cups 28 project upwardly through the table 27, and are connected to a vacuum supply 35 through the base 34 on the valve 30. The ends of each of a pair of short links 36 are affixed to the chambers 33, and the opposite ends thereof are pivotally mounted by a pin 38 to a stationary part of the apparatus (not shown). A second pin 40 pivotally mounts one end of a tie link 42 at an intermediate point on one of the short links 36, and a third pin 44 passes through the yoke at the opposite end of the tie link 42 to secure it to one end of an actuating lever 46. The lever 46 is pivotally mounted adjacent is opposite end upon a fixed post 48, and it is biased upwardly by the coil spring 49 which in turn is secured to a stationary element, not shown. An actuating plunger 50 is mounted adjacent the valve 30 for contact therewith, and it is spring-loaded to accommodate over-travel of the valve 30. In its position (shown in FIG. 1) away from the plunger 50, the valve 30 opens the cups 28 to the vacuum source 35; moving the valve 30 against the plunger 50 (to the position of FIG. 5) shifts the valve mechanism to block the vacuum supply 35 and also to vent the chambers 33. This permits intermittent gripping and release of carton blanks in a manner to be more fully described hereinafter.

Pivotally mounted adjacent the inner portion of the feed mechanism (upon structure not shown) is an angle bracket 54 having a pressure roller 56 supported in its upper end and a cam follower roller 58 adjacent the opposite end thereof. The bracket 54, and thereby the pressure roller 58, is generally downwardly biased by the coil spring 59, the opposite end of which is fixed to structure that is not illustrated. A rotary cam wheel 60 is mounted to lie vertically between the angle bracket 54 and the actuating lever 46, and the circumference of the wheel 60 has a secantally flattened surface portion 62 thereon. The cam wheel 60 also has an inner egg-shaped cam element 64, against which the cam follower roller 58 is biased by the spring 59 to control the movement of the angle bracket 54. Mounted intermediate the length of the actuating lever 46 is a second cam follower roller 66, which is biased against the circumferential surface of the cam wheel 60 by the spring 49 to control the movement of the lever 46.

In FIG. 1, the cam wheel 60 is positioned with the cam follower wheel 66 resting at the center of the secantal flattened surface 62, permitting the cups 28 and the valve 30 to be biased upwardly by the spring 49. In this position, the cups 28 contact the bottommost blank 10 in the magazine 22 and the valve 30 allows a vacuum to be drawn through the cups 28, so that the vacuum force engages the blank 10 upon the cups 28. In the same position of the wheel 60, the cam follower roller 58 is at the apex of the egg-shaped cam element 64, pivoting the angle bracket 54' upwardly against the force of spring 59 and lifting the pressure roller 56 away from the rotating transport roller 68, with which 7 it cooperates and which is centrally mounted upon a shaft 69.

Turning of the cam wheel 60 in a clockwise direction to the position of FIG. forces the cups 28 downwardly to pivot the blank through a small angle to position it upon the circumferential surface of transport roller 68 which projects into the plane thereof; it also blocks the vacuum supply 35 and vents the chambers 33 to release the carton blank 10. At the same time, the cam element 64 permits the pressure roller 56 to pivot to a position over the blank 10, forcing the latter firmly against the transport roller 68 which is then effective to drive the blank 10 forward in the machine. Continued rotation of the wheel 60 causes the cups 28 to grip the subsequent carton blank in the magazine 22, and moves the pressure roller 56 out of the way to permit the blank to pivot downwardly to the table 27. It is significant that the present mechanism minimizes the stroke of the gripping means, i.e., the distance through which the carton blanks must travel for feeding thereof, and thereby shortens the time necessary and increases the number of cartons which may be formed by the machine in a given time period.

After release of the carton blank 10, the transport roller 68 and pressure roller 56 cooperate to drive it forward to deliver it into the nip of a pair of horizontal transfer rollers 70,70, which are rotationally mounted on respective vertically aligned shafts 72, 72'. The transfer rollers 70, 70' cooperate to carry the blank 10 further along the travel path of the apparatus, and the blank 10 is thereupon engaged in the nip of the next pair of transfer rollers 74, 74 that are mounted on the parallel horizontal shafts 76, 76'; the transition through this station is depicted in greater detail in FIGS. 6A 6C, towhich particular reference will hereinafter be made.

An elongated wedge-shaped mandrel 78 is spaced above the table 27 on each side of the transfer rollers 70, 74, the distance therebetween being sufficient to permit passage of the blank 10 therethrough. A flap folding assembly,.generally designated by the numeral 80, is positioned on each side of the machine (the assembly farthest from the viewer being shown in FIGS. 1 and 7, and the other assembly being shown in FIGS. 6A and 6B), and it includes an elongated folding mandrel or head 82 that has an upper shoulder 84 and a lower shoulder 86 extending longitudinally therealong to provide an elongated inner folding ridge or element 88 thereon. With reference in addition to FIG. 7, it is seen that the head 82 has a pair of legs 89 depending from it, each of which has two vertically aligned apertures 90 provided therein; each leg 89 is connected to a pair of 'upper links 92 by short pins 94 extending therethrough, and to a pair of lower links 96 by a similar set of pins 94. The opposite ends of the links 92, 96 are pivotally mounted upon a U-shaped frame 97 that has a pair of spaced L-shaped elements 98, the links 92 being mounted by an elongated shaft 100. The shaft 100 passes through a short collar 102 mounted between the L-shaped elements 98, which has a short, inwardly projecting boss 104 which is seated within the yoke 106 of an actuating rod 108. The collar 102 and links 96 are rigidly attached to the shaft 100 and a suitable pin pivotally secures the boss 104 in the yoke 106, so that up and down reciprocal movement of the rod 108 through the base of the frame 97 pivots the shaft 100 and thereby the links 96. This movement is transmitted to the legs 89 of the folding head 82, and tends to move them upwardly. Since the outer edges of the blank 10 ride in the upper shoulders 84 of the heads 82, the upward movement thereof breaks" or bends the outer edges (i.e., the edge flaps 11) of the blank 10 against the mandrels 78. Upon continued upward movement of the legs 89 the links 92 pass a horizontal position, whereupon they tend to pull the heads 82 inwardly so that the flaps ll of the blank 10 are tucked under the lower shoulders 86 of the head 82 and upon the upper surfaces of the mandrels 78; this is the condition depicted in FIG. 6B. The movement described is reversed upon downward actuation of the rod 108, whereupon the flaps 11, 11' so formed remain in a generally vertical attitude.

A suitable clevis 112 has a threaded stud 107 projecting upwardly from it, the end of the stud 109 being engaged in the corresponding end of the rod 108 and having a nut 1 10 thereon that is tightenable against the rod 108 for adjustment. The clevis 112 is supported upon a suitable angle bracket 114 which is pivotally supported intermediate its ends upon a fixed post 116, and the opposite end thereof rotatably seats a follower roller 118. As can be seen in FIG. 1, the cam wheel 60 has a second egg-shaped cam element thereon in addition to the cam element 64 previously described; however, the cam elements 64, 120 have been illustrated separately in FIGS. 5 and 7 respectively for clarity of description. It will now be appreciated that rotation of the cam wheel 60 not only operates the blank feed mechanism previously described, but that it also reciprocates the actuating rod 108 in a properly timed sequence to produce the flaps 11, 11' at the first folding station of the machine. It should also be understood that operation of the folding heads 82 occur intermittently during uninterrupted movement of each blank 10 thereby, and that the dimensions of the elements of the machine and the timing of the sequential moves thereof are selected in such a manner as will make this possible. The same holds true of the subsequent stations of the machine to be described hereinafter; i.e., the blanks travel continuously entirely through the machine without interruptions for any of the various operations performed thereon.

During the subsequent progress of the carton blank 10 through the machine, the driven rollers 74, 74 carry it to a gluing station wherein the right hand flap 11 (in FIG. 6C) is first folded inwardly to a horizontal position by the downwardly angled upper flange 122 of the plow 124 (best seen in FIG. 1) through which the blank 10 passes. Thereafter, the blank 10 is delivered into the nip of another pair of transport rollers 126, 126 mounted on horizontal shafts 128, 128', as it is best seen in FIG. 8; since the shaft 128 is supported adjacent only one of its ends, the tubular housing 129 is also provided thereabout to furnish added support. A housing 130 at the gluing station encloses a glue container (not shown), which may be adapted for the use of a hot melt-type of adhesive by the provision of associated heating means, if so desired. A glue applicator wheel 132 is fixed on the driven shaft 134, and the wheel 132 communicates with the glue container in the housing 130 to pick up glue on its circumferal edge surface 136, it being appreciated that doctor blades, gaskets and the like are provided where necessary to control the rate of glue pick up and to prevent leakage of glue around the wheel 132. A support or backup roll 138 is vertically 9 aligned under the glue wheel 132, and rotation of the rollers 126, 126' carries the carton blank 10 from the plow 124 so that the flap 11 passes between the wheel 132 and support roll 138, whereby glue is transferred from the edge surface 136 to the outer surface of the flap 1].

FIGS. 1 and 2 depict an offset bracket 140 that is rigidly affixed on the apparatus (by means not shown) to extend over the bed or travel path thereof at a location downstream of the glue applicator wheel 132, and to support therebelow an elongated stationary mandrel generally designated by the numeral 142 and most clearly illustrated in FIG. 10. Adjacent its rear end, the mandrel 142 has a pair of angle brackets 144 secured to the sides with bolts 145 and extending outwardly therefrom, and the brackets 144 have threaded apertures 146 therethrough in which the bolts 148 are engaged to secure the mandrel 142 to the bracket 140. The lower rear edge 150 of the mandrel 142 is bevelled downwardly (in a transverse plane) to ensure passage of the carton blank 10 thereunder, as will be described hereinafter. The rear portion 152 of the mandrel 142 is somewhat thicker than is the front portion 154 thereof, and it is fabricated with a vertically inwardly bevelled portion 156 between the portions 152, 154 to provide gradual transition surface. The upper part of the front portion 154 also has a bevelled surface 158 to provide a top edge 160 thereat of reduced dimensions, the function of which will become clear hereafter.

After passing from between the nip of the transfer rollers 126, 126, the blank 10 passes under the mandrel 142 and progresses forwardly (downstream) in the apparatus under the cooperative influence of the bottom transfer rollers 162, 164, which are best shown in FIG. 2 and are mounted respectively on shafts 163, 165. With particular reference to FIGS. 9A and 9B, one of a pair of side wall folding assemblies, generally designated by the numeral 166, ispositioned on each side of the apparatus, as was true of the flap folding assemblies 80 previously described. Each assembly 166 includes an elongated right angle folding head 168 that has a pair of legs 170 depending adjacent each end thereof. Since the movement that is required in the folding heads 168 is somewhat different than that necessary in the heads 82 of the assemblies 80, the supporting structure is also modified somewhat therefrom; however, the mechanism for moving the heads is virtually the same and so has not been illustrated in order to minimize the complexity of the drawings. Each of the legs 170 has a pair of axially aligned apertures 172 in which are mounted short pivot pins 174. The pins 174 pivotally secure each of the legs 170 to a set of short upper and lower links 176, the opposite ends of which are pivotally secured to appropriate mounting structure (not shown). This is accomplished with pins 178 in the case of the upper links 176, and with a shaft 180 in the case of the lower pair of links 176. Like the shaft 100, shaft 180 extends longitudinally between both of the legs 170 attached to one of the heads 168, and the shaft 180 is fixed therein so that pivoting of it will operate the head 168; an actuating assembly similar to that employed for the folding head assembly 80 may be used for that purpose. When the blank 10 is appropriately positioned relative to the heads 168, a cam element on a rotating member or other suitable means (not shown) drives the actuating assembly (also not shown) which in'turn pivots the shafts 180 in opposite directions to simultaneously lift the folding heads 168 from the position shown in FIG. 9A to that of FIG. 9B. The vertical elements 182 of the heads 168 are thereby moved upwardly and inwardly toward one another (due to the link arrangement) as a result of which the carton blank 10 is folded about the mandrel 142 with the front and back walls 13 thereof pressed against the sides of the mandrel 142 by the vertical elements 182.

The pressure of the glue wheel 132 on the flap 11 has the effect of compressing it further than the flap 11 as a result of which the flap 11' springs back more than does the flap 11 (to which the glue is applied). As a result, when the walls 13 are folded to vertical positions, the flap 11 passes beneath the flap 11 so that the glue applied to the former is present therebetween. Immediately after the walls 13 are positioned to so relate the flaps 11, 11', they are forced into contact with one another by the channeled pressure plate or bonding member, generally designated 184, that is reciprocally supported by the arm 186 (which in turn is supported for intermittent vertical movement by means not shown). The plate 184 is elongated so as to contact the flap 11' over is entire length simultaneously; this ensures that the bond is formed at the same time at all of the points on the flaps 11, 11' that are ultimately to be secured together, which in turn ensures that the front and back walls 13 are essentially parallel and that a square or rectilinear carton 12 is produced. The plate 184 has an internal U-shaped channel 186, which is widened by bevelled surfaces 188 at its mouth to facilitate entry of the flaps 11, 11 thereinto, and the means intermittently moving the plate 184 may be timed and driven by an appropriate camming mechanism; illustration thereof is believed I to be unnecessary since conventional means of the type already described may be employed. It should be understood that the plate 184 is only one of many types of bonding means that may be employed to effect the initial contact between the flaps ll, 11. The significant factor is that the bonding means is designed to produce initial contact in the ultimately desired position of the flaps, so that a very quick setting or immediate tack adhesive may be used; to do so the leading ends of the carton flaps may not be bonded before subsequent portions thereof, as occurs with the plowing or other progressive-effect devices. Attempts have been made in the past to achieve a square relationship at initial contact with a progressive folding device by aligning the flaps in close proximity prior to contact or by making the fold gradually. However, such an approach necessitates using an unduly long travel path, which undesirably reduces the productivity of the apparatus and increases its cost; these are two disadvantages that are minimized with mechanisms of the type herein described. Although a bonding member having an elongated engagement surface (parallel to the travel path) is most desirable for this purpose, a member having one or more contact points therealong may be suitable, depending upon the carton configuration and the operation (i.e., timed sequence) of the apparatus.

The carton 12 that is so formed thereafter moves along the mandrel 142 to pass between a pair of driven belts 190, 192, which function as drive and pressure belts respectively. The lower drive belt 190 is mounted about a set of horizontally spaced pulleys 194 (the first of which is shown in FIG. 11); the pulleys 194 are sup-- ported upon shafts 195, 195 and, have a number of pressure rollers 196 therebetween. The rollers 196 maintain the portion of the belt 190 that spans the pulleys 194 in a sufficiently elevated position to contact the lower edge or sidewall 15 of the carton 10, and in turn to urge the carton tightly against the corresponding surface of the mandrel 142. Similarly, the upper pressure belt 192 travels about pulleys 198 that are mounted on spaced shafts 199 and 199' and between which are positioned pressure rollers 200; the rollers 200 press downwardly upon the intermediate portion of the belt 192, which in turn bears upon the flaps 11, 11' to ensure complete bonding thereof during forward progress of the carton 12 through the machine. Stationary side plates 202, 202' are mounted by brackets 204 to parts of the machine (not shown), and ensure close conformity of the carton 12 to the dimensions and configuration of the rear portion 152 of the mandrel 142 with which they, and the belts 190, 192, cooperate; FIG. 1 1 illustrates this relationship in detail.

The carton 12 then progresses to a collapsing station at which a pair of vertically reciprocating fingers 206 first cooperate with the bevelled surface of the front portion 154 of the mandrel 142 to fold the carton to a semi-collapsed state. As is seen in FIGS. 12A and B, one of a pair of fingers 206 is positioned on either side of a driven transfer roller 208 that is mounted on a shaft 210. The roller 208 contacts the upper flap 11' and conveys the carton 12 to a position at which it is fully aligned over the forward portion 154 of the mandrel 142. Thereupon, the fingers 206 simultaneously move downwardly from the position of FIG. 12A (shown in phantom line in FIG. 12B) against the flap 11' to the full line position of FIG. 123, to fold it and flap 11 (which are bonded together) over the relatively sharp top edge 160 and (although not illustrated) thereafter against the bevelled upper part 158, the side plate 202 being elongated to extend behind the forward portion 154 of the mandrel 142 and thereby assist in this operation. The roller 208 then moves the carton 12 into the nip of the two vertical pressure rollers 212, mounted upon driven shafts 214, whereby the carton 12 is pressed into a completely collapsed and flattened condition, which is desirable for packaging and storage thereof prior to use. This operation is illustrated in' FIG. 13 and, as is seen in FIGS. 1 and 2, after discharge from the vertical rollers 212 the finished, collapsed cartons fall into a receptacle 216, where they are collected and stacked.

FIGS. 14 A F illustrate the operations carried out to produce a carton ready for filling from a blank, in accordance with the invention. Thus, FIG. 14 A corresponds to FIG. 3 and shows the blank 10 with suitable score lines formed therein prior to folding, and FIG. 14 F corresponds to FIG. 4 and shows the completed carton 12 ready for filling. FIG. 14 B shows the blank 10 after the initial folding operation (shown in FIGS. 6 A C) whereby the flaps 11, 11' are deformed upwardly, and FIG. 14 C illustrates the blank 10 after it leaves the glue-applying operation described in detail with reference to FIG. 8. The phantom line representation of FIG. 14 D depicts the carton 10 before operation of the secondary folding mechanism, and the full line representation shows it thereafter and with the flaps 11, 11' bonded together, which operations are best illustrated by FIGS. 9 A and 9 B. Finally, FIG. 14 B shows the carton 12 in the fully collapsed state that occurs as a result of the operations described with reference to FIGS. 11

13; thereafter, and prior to filling, the carton 12 is opened into the condition illustrated by FIGS. 4 and 14 F.

The power for the entire apparatus may be derived from a single motor (not illustrated) which drives the primary drive shaft 218 on which the rotary cam wheel 60 is affixed. Although the belts, gears and other means used to transmit power from the primary drive shaft 218 are in some cases schematically and fragmentarily illustrated, for the sake of simplifying the drawings, the manner in which such transmission is effected will be clear from the following description.

With particular reference to FIGS. 1 and 2, a drive chain 220 is engaged about a sprocket 222 that is affixed on the primary drive shaft 218, and about a pair of sprockets 224 secured on shafts 69 and 72', so that rotation of the shaft 218 drives the transport roller 68 through shaft 69 as well as the lower transport rollers 70' through the shaft 72'. Inwardly of the sprocket 224 on the shaft 72' is a spur gear (not seen) that engages the meshing gear 226 located thereabove and affixed on shaft 72, through which power is transmitted to the transfer roller 70 and the sprocket 228 at the far side of the apparatus. A chain 230 couples the sprocket 228 to the adjacent sprocket 232 on the shaft 76, by which the transfer roller 74 is driven, and this power is transmitted to the lower transfer roller 74' on shaft 76'v through the spur gears 234, 234' on the opposite ends of shafts 76, 76'.

A second sprocket (not shown) is affixed on the primary drive shaft 218 and engages the chain 236 which extends forwardly to drive a secondary drive shaft 238 through a sprocket 240 fixed thereon. A number of appropriately spaced sprockets (each designated 242) are secured on the drive shaft 238 to transmit power through a number of chains, the one of which that is designated 244 being engaged about sprocket 246 on the lower shaft 128, through which transport roller 126 and support roll 138 are driven. At the near side of the machine a spur gear (not seen) drives a larger gear 250 thereabove (shown in FIG. 2) to rotate, through the shaft 134, the glue applicator wheel 132 and at the far side, the power is transmitted to the shaft 128 and upper transport roller 126 thereon through a set of gears 252. A sprocket 254 is secured on the shaft .128 at the outer end adjacent to the gear 252, about which is engaged a chain 256 which isalso engaged about a sprocket 258 on the shaft 199. A second sprocket 260 is fixed on the shaft 199 adjacent to sprocket 258, and a chain 262 couples it to the shaft 199", aligned horizontally therewith, through sprocket 264; the shafts 199, 199' thereby drive the pulleys 198, which in turn rotate the upper pressure belt 192.

The lower shafts 195, 195' have sprockets 264 secured thereon, which are'visible in FIG. 2 because the shafts 199, 199' directly thereabove terminate at a pointshort of the near ends of the shafts 195, 195 and are supported thereat in bearings 266. The sprockets 264 are operatively interengaged by the chain 268, and another sprocket 270 on the shaft 195 adjacent to the sprocket 264 thereon is coupled to the secondary drive shaft 238 by a chain 272. The chain 272 is engaged about one of the sprockets 242 on the shaft 238, and rotation thereof thereby drives the lower drive belt through the shafts 195, and the pulleys 194 thereon. Finally, a sprocket 274 is secured on the far end of each of the shafts 163 and 165, and they are driven by a chain 276 that passes about them and a sprocket 242 (not shown) on the secondary drive shaft 238. As a result, the shaft 236 transmits power to the shafts 163, 165, whereby the transfer rollers 162, 164 are driven. It will be appreciated that the opposite ends of the shafts 163, 165 are supported in appropriate bearings 266 and that other bearings, hubs, thrust washers, and the like are provided throughout the machine where they are needed or desired, in accordance with conventional mechanical practice.

Second Embodiment Turning now in detail to FIGS. 18 of the appended drawings, therein illustrated is a second embodiment of the apparatus of the invention utilizing somewhat different feeding, folding and gluing mechanisms than those of the First Embodiment. The portions of the machine specifically illustrated in FIGS. 11 13 and previously described are common to both embodiments, and the drive mechanisms, timing elements, and the like are not depicted in detail with regard to the present embodiment because the specifics thereof will be apparent to those skilled in the art in view of the foregoing description. Among the particular advantages of this embodiment are even greater speed, and a design that is especially appropriate for the production of relatively large cartons.

The machine illustrated employs an elongated mandrel, generally designated by the numeral 300, that has its leading end directly adjacent the feed mechanism, generally designated 302, and is supported thereat by a bracket 304 that is rigidly affixed to the apparatus (by means not shown). A lower leading edge portion of the mandrel 300 is bevelled to ensure entry of carton blanks, and it has an elongated channel 310, that is generally U-shaped in cross section (as is best seen in FIG. 18 A) extending inwardly from the bottom edge. A multiplicity of rollers 312 are rotatably supported therewithin upon pins 314 at spaced locations along the length of the channel 310, and a driven roller 316 is rotatably mounted upon a shaft 318 directly under each of the rollers 312; the sets of rollers 312, 316 cooperate to propel blanks along the length of the mandrel 300. Extending inwardly from the top edge of the mandrel 300 intermediate its length is an elongated folding groove 320 that is generally V-shaped in cross section (as is best seen in FIGS. 18 C and 18 D).

The vacuum system of the feed mechanism 302 was described in detail with reference to the First Embodiment, and no repetition thereof is necessary here; however, a different type of mechanism is utilized to carry the blanks from the initial feed position into the nip of the first set of rollers 312', 316', and this will be described. Thus, one of a stack of carton blanks (such as is illustrated in FIG. 17 A and generally designated by the numeral 322) is extracted from the bottom of the magazine 324 by the vacuum cups 326 of a vacuum assembly (not shown). A nipper assembly, generally designated 328, then picks up the blank 322 and carries it forward, a high level of speed being attained by the superimposition of two driving efiects therein. Each of a pair of nipper rolls 330 is centrally supported upon a shaft 331, which in turn are rotatably mounted in bearing housings 333. The housings 333 are supported (by means not shown) above a drive roll 332 for pivotal movement through a very small are relative thereto, and a timing belt 334 passes about a pulley 335 on the upper shaft 331 and the drive roll 332 to rotate the nipper rolls 330 in the proper direction. It will now be appreciated that the nipper rolls 330 are properly timed to move toward the blank 322 (to the phantom line position of FIG. 15) each time a blank 322 is extracted from the magazine 324, and to thereafter move to the full line position. The rotating nipper rolls 330 grip the blank 322 and drive it forward, and the combination of such a driving effect with the forward pivoting of the set of rolls 330 provides a very high linear feed rate and also reduces the necessary residence time of the nipper assembly 328 under the magazine. Since in such a machine, the speed of the feed operation is often the limiting factor, use of the mechanism described may permit a maximum output to be obtained therefrom.

As is seen in FIG. 17 A, the blank 322 has a number of longitudinal score lines 336 defining thereon front and back walls 338, a side wall 340, a small flap 32 and a large flap 344, each of which may be considered a wall portion defined by lines extending in a direction that will be parallel to the travel path. Transverse score lines define closing tabs or flaps 348 at the ends thereof. The blank 322 is seen to be relatively long, and the overall dimensions thereof are relatively large, compared to the blank 10 utilized in the First Embodiment; the folding mechanisms of the instant apparatus are particularly well suited to handle blanks of the size and type illustrated.

As is best seen by reference to FIGS. 18 A,B,C, folding of the front and back walls 338 about the mandrel 300 is accomplished in two stages, and before either of the flaps 342, 344 is folded. By the arrangement herein provided the folding operations may be overlapped somewhat (i.e., the mechanism for one phase may be retracting while that for the subsequent phase is operative) which has the efi'ect of rendering the machine operation even more efficient and thereby maximizing its output per unit of time. To accomplish the folding of the front and back walls 338 two sequentially located sets of folding assemblies, generally designated by the numerals 350, 352, are employed, each set consisting of an assembly on each side of the travel path, as was previously described with reference to the First Embodiment and as will be apparent from FIGS. 18. The folding assemblies each include a U-shaped actuating bracket 35$ and an elongated folding mandrel or head 356 having depending legs 358 by which it is pivotally mounted upon the actuating bracket 354. As the blank 322 passes over the first set of folding assemblies 350 (in the relationship depicted in FIG. 18 A) the heads 356 are raised upwardly and inwardly by means (not shown), operating the actuating bracket 354 to bring the front and back walls 338 to the position of FIGS. 15 and 18B, wherein they are at an angle of about relative to the sidewall 340. When thereafter the blank 322 moves to the second set of folding assemblies 352, the folding heads 356 thereof are brought upwardly and inwardly to fold the walls 338 to upright positions against the sides of the mandrel 300, and this relationship is depicted in FIGS. 15 and 18 C.

Directly adjacent the second set of folding assemblies 352 is a flap folding ram, generally designated by the numeral 360, which includes an elongated folding blade 362 on one end of a short shaft 364 that passes through a bushing and is attached at its opposite end to a tang The tang 368 is pivotally mounted in the yoked end 370 of an angle bracket 372, which (along with the bushing 366) is supported on the apparatus by means not shown. When the blank 322 is properly positioned on the mandrel 300, the ram 360 is actuated (by means not shown) so as to push the shaft 364 through the bushing 366, and thereby to drive the blade 362 against the outside of the small flap 342 simultaneously over substantially its entire length, thereby folding the flap 342 into the V-shaped groove 320 in the top of the mandrel 300; i.e., the ram moves from the full line to the phantom line positions shown in FIG. 18 D.

As the blank 322 thereafter passes along the mandrel, the sloped end surface 374 defining the groove 320 plows the flap 342 upwardly to a right angle position (with respect to the front wall 338) between the top surface of the mandrel 300 and the hold down finget 376 of the hot melt extruder, generally designated 378 and supported thereabove by means not illustrated. The extruder 378 comprises a housing 380 having heating means and a glue reservoir (not shown) therein, and a small nozzle 382 depends from the housing- 380 to extrude melted adhesive upon the flap 342 as it passes behind the finger 376. Thereafter, the blank 322 passes adjacent a push rod assembly, generally designated 384, whereat the entire length of the large flap 344 is pushed simultaneously over the small flap 342 to ensure contemporaneous contact and that the resulting carton (generally designated 386 and illustrated in FIG. 17 C) is desirably rectilinear. The push rod assembly includes an elongated rod 388 that is centrally secured to one end of a short shaft 390, which in turn is slidably mounted in a bushing 392 and is affixed at its opposite end to a tang 394. At the proper time an operating mechanism (not shown) attached to the tang 394 pushes the shaft 390 through the bushing 392, driving the rod 388 against the flap 344; this bends the flap 344 to a right angle position, and the rod 388 continues over the flaps 344, 342 for a short distance to form a preliminary bond therebetween, i.e., the push rod 388 moves from the full line to the phantom line position shown in FIG. 15. Then the carton 386 progresses to mechanism such as is shown in FIGS. 11 13 to ensure complete bonding and finish the manufacture thereof, in the manner described with reference to those figures. FIG. 17 B illustrates the blank 322 at an intermediate, stage of production after application of the adhesive and before folding of the flap 344 into contact with flap 342.

In FIGS. 19 20, there are illustrated other embodiments of the apparatus utilizing reciprocating members which move continuously about an axis, although intermittently toward and away from the travel path of the carton, to support and move the folding and bonding members.

In FIG. 19, an elongated rectangular pressure plate or bonding member 400, similar to the element designnted 184 in FIGS. 9A and 9B, is supported adjacent its ends eccentrically by crank wheels 402. The wheels 402 are rotatably mounted upon axles 404 and have short studs 406 extending axially from one side thereof and received in bushings 408 in the plate 400. An elongated stationary mandrel 409 is positioned below the plate 400, and a number of drive rollers 410 are located closely adjacent the lower edge of the mandrel 408. As will be readily apparent, rotation of the drive rollers 410 in, the indicated counterclockwise direction will propel the carton blank 412 from right to left along the mandrel 408 by contact therewith. Due to the eccentric mounting of the pressure plate 400 upon the crank wheels 402, continuous rotation thereof will intermittently raise the plate 400 from the position illustrated and return it thereto. As a result, if movement of the plate 400 is appropriately timed in sequence with the feed of carton blanks, simultaneous bonding of prepared flaps of the carton blank 412 can be effected thereby in the manner described hereinbefore.

In addition to continuous operation, the illustrated mechanism also has the advantage of reducing drag upon the moving blanks. Clockwise rotation of the crank wheels 402 will impart a right to left component of movement to the plate 400 as it contacts the blanks 412, thus eliminating even the small component of drag that could result from contact during simple up-anddown reciprocal movement of the plate 400.

It should be appreciated that the type of mechanism illustrated in FIG. 19 can be employed, in appropriate instances, for the folding of flaps rather than simply to cause contact to occur therebetween. Thus, for example, if the crank wheels 402 and plate 400 were supported at an appropriate angle they could be used in place of the ram assembly 360 shown in FIGS. 15 and 18]), or in place of the push rod assembly 384 of FIGS. 15, 16 and 18B.

Turning finally to FIG. 20, a second continuous operation type of mechanism is illustrated, which is especially suited for flap folding, carton collapsing, and the like, and is generally designated by the numeral 414. The mechanism 414 includes a curved head 416 (elongated in a direction perpendicular to the plane of the sheet of drawings) rigidly affixed to one end of a support beam 418, and a shaft 420 having portions extending perpendicularly from both sides of the beam 418. The ends of the shaft are journalled in bearings 422, which are mounted in the two upwardly projecting side posts 424 (only one of which is visible) of a U-shaped mounting fixture, the base 426 of which is supported upon a frame portion 428 of carton forming apparatus of the type hereinbefore described and illustrated.

Also mounted on the apparatus adjacent the mechanism 414 are an elongated stationary mandrel 430 and a set of drive rollers 432 (only one is visible) positioned therebeneath. The drive rollers 432 convey carton blanks, such as 434, along the bottom edge of the mandrel 430 and past the mechanism 414. The beam 418 rotates at the proper speed and in a counterclockwise direction to contact the underside of the blank 434 during its travel past the mechanism 414, thereby bringing the contacted portion upwardly against the stationary mandrel 430 to produce the desired fold in the carton blank 434.

Thus, it can be seen that the present invention provides a carton forming apparatus wherein flaps of the carton blank are folded along the entire length of the ultimate fold line substantially simultaneously to provide parallel fold lines and wall portions that are parallel, with respect to other portions of the blank. Contact of surfaces to be bonded is effected simultaneously over substantially the entire adherent area thereof so that proper alignment is attained, and relatively small apparatus that operates rapidly and substantially continuously to provide a high level of carton productivity, is thereby furnished. Thus, rates on the order of 500 cartons per minute are feasible. In addition, the invention provides a method wherein a multiplicity of cartons having a rectilinear cross section can be formed from blanks in rapid succession, and in which an immediate tack adhesive that allows no slip adjustment may be employed to bond wall portions of each blank to one another in proper alignment upon initial contact.

Having thus described the invention, we claim:

1. Carton forming apparatus comprising:

A. a support providing a travel path for carton members;

B. a folding mandrel having a folding surface;

C. means for intermittently moving said folding mandrel toward said path into a position with its folding surface effectively parallel to said path for engagement with a wall portion of a carton blank during its travel therealong, said folding surface contacting said wall portion to simultaneously move the entire length thereof inwardly, and to produce the entire length of the fold therein at one time;

D. means along said path for rendering adherent an area of a surface of at least one of the wall portion and of a cooperating portion of the carton blank to be bonded thereto;

E. a bonding member having an engagement surface for effecting contact between the wall portion and the cooperating portion of the carton blank;

F. means supporting said bonding member in a position along said path downstream of said adherentrendering means for intermittent movement thereof inwardly toward said path to effect said contact of wall and cooperating portions over substantially the entire adherent area thereof at the same time, to effect simultaneous bonding thereat;

G. transport means for continuously moving a multiplicity of carton members in rapid succession along said travel path; and

H. automatic means driving said transport means, and operating said intermittently moving means and said bonding member support means in timed sequence.

2. The apparatus of claim 1 wherein said support provides a travel surface adjacent the beginning of said travel path, and wherein said apparatus additionally includes a feed mechanism for the carton blanks comprising a magazine for supporting a stack of carton blanks at an acute angle relative to said travel surface, and with the trailing edge of the bottommost carton blank resting thereupon, means for gripping the bottommost carton blank and pivoting it about its trailing edge to an initial position along said travel path and thereupon effecting the release thereof, said magazine permitting removal of the carton blanks singly therefrom by said gripping means.

3., The apparatus of claim 2 wherein said gripping means comprises an intermittently evacuable cup having its open end adjacent said magazine, means for intermittently moving said cup into contact with the bottommost carton blank, and means for evacuating said cup to engage a blank thereupon.

4. The apparatus of claim 2 wherein said feed mechanism additionally includes delivery means comprising a driven transport roller positioned with its circumferential surface projecting upwardly into the plane of said travel surface, and a pressure roller movable to a position over the released carton blank to press it against said circumferential surface of said transport roller and thereby to carry the carton blank from said initial position to said transport means.

5. The apparatus of claim 2 wherein said feed mechanism additionally includes delivery means comprising a pair of adjacent driven rollers having their axes aligned generally perpendicularly to said travel path to provide a nip therebetween that also extends generally perpendicularly to said path, and means mounting said pair of rollers for intermittent reciprocal movement toward said magazine to a position wherein the released blank is gripped in said nip, and away from said magazine to deliver the blank to said transport means.

6. The apparatus of claim 1 including at least a second one of said folding mandrels to provide a pair thereof, said folding surfaces of said mandrels being spaced transversely on opposite sides of said travel path and said mandrels being simultaneously movable by said intermittent mandrel moving means toward said path to contact, with said folding surfaces, wall portions along opposite sides of the blank and to produce the entire lengths of the folds therein at one time.

7. The apparatus of claim 6 including at least a second pair of said folding mandrels spaced from said firstmentioned pair along said travel path.

8. The apparatus of claim 7 wherein each of said firstmentioned pair of folding mandrels moves inwardly only to an intermediate position toward said path to partially fold the wall portion of the carton blank engaged thereby, and wherein one of said second pair of folding mandrels moves inwardly toward said path from the plane of each of said intermediate positions to fold the same wall portions that were engaged by said firstmentioned pair.

9. The apparatus of claim 1 wherein said folding surface is substantially equal in length to the wall portion of the carton blank to be engaged thereby, and wherein said apparatus includes a relatively narrow stationary mandrel element that is generally transversely aligned with said folding surface and is mounted inwardly of said travel path and above the upper plane thereof to permit the blank to pass therebetween with portions thereof extending outwardly of said stationary mandrel element, said folding mandrel being mounted on said intermittent moving means for movement from a position downward and outward of said stationary mandrel element to a position upward and inward thereof, whereby movement of said folding mandrel to said upward and inward position folds the wall portion of a carton blank extending outwardly of said stationary element at least partly thereabout.

10. The apparatus of claim 9 wherein said folding I surface is provided by an inwardly projecting elongated ridge that extends parallel to said travel path and cooperates with the remainder of said folding mandrel to form an upper shoulder thereabove and a lower shoulder therebelow, the carton blank riding within said upper shoulder with said folding mandrel in said downward and outward position, and the underside of said ridge bearing against the carton blank wall portion and forcing it about said stationary mandrel element in said upward and inward position thereof.

11. The apparatus of claim 9 wherein said stationary mandrel element has a groove formed therein that extends along said travel path, and wherein said apparatus additionally includes a ram mechanism having an element that is reciprocally movable perpendicularly to said path into and from said groove, said element of said ram mechanism being configured and positioned to simultaneously contact substantially the entire 19 length of a wall portion of the carton blank to fold it about said stationary mandrel element and into said groove to form the entire length of the fold therein at one time.

12. The apparatus of claim 1 wherein said adherentrendering means is a hot melt adhesive dispenser.

13. The apparatus of claim 1 wherein at least one of said means moving said folding mandrel and said means supporting said bonding member includes a mounting member supported for continuous rotation about an axis thereof, said mounting member mounting one of said folding mandrel and said bonding member for movement thereof intermittently toward and away from said travel path during different portions of the cycle of rotation of said mounting means.

14. In a method of forming cartons from carton blanks, the steps comprising:

A. continuously moving a multiplicity of carton blanks in rapid succession along a travel path;

B. during movement thereof along said path, moving a mandrel intermittently toward said travel path to engage, with a folding surface thereof, each of the blanks at a wall portion defined by a line extending parallel to said path and over substantially the entire length thereof, and folding the entire wall portion inwardly toward said path along said line at the same time;

C. rendering adherent an area of a surface of at least one of said wall portion and of a cooperating portion of the carton blank to be bonded thereto; and

D. during movement of the carton blank along said path, moving a bonding member intermittently toward said path to effect contact between said wall portion and said cooperating portion of each carton blank over substantially said entire adherent area thereof at the same time, and thereby effecting simultaneous bonding thereat, said movements of carton blanks, mandrel and bonding member occurring in timed sequence.

15. The method of claim 14 wherein in said step B each of the blanks is engaged over substantially the entire length of wall portions at opposite sides thereof defined by a pair of said lines extending parallel to said path, to simultaneously fold said wall portions in their entirety inwardly toward said path, wherein said surface is rendered adherent by application of an adhesive thereto, and wherein said method additionally includes the steps of:

E. automatically feeding a multiplicity of carton blanks in rapid succession to said travel path; and

F. during movement of the blanks along said path subsequent to said step B and prior to said step D, engaging each of the blanks over substantially the entire length of second wall portions that are defined by a second pair of lines extending parallel to said path along the opposite sides of each blank inwardly of said first-mentioned pair of lines, and folding the entire second wall portions inwardly toward said path at substantially the same time.

16. The method of claim 14 wherein said step B is effected in two successive stages.

17. The method of claim 15 wherein in said automatic feeding step E, each blank is contacted with a member that is continuously moving in one direction, which member is in turn being reciprocated along said travel path toward and from a source of the blanks, superimposition of the movement of the continuously moving member from the source of blanks upon the continuous movement thereof imparting to the blanks a forward speed that is the resultant of the two motionproducing effects.

18. The method of claim 14 wherein said surface area of said wall portion is rendered adherent by application of a hot melt adhesive thereto. 

1. Carton forming apparatus comprising: A. a support providing a travel path for carton members; B. a folding mandrel having a folding surface; C. means for intermittently moving said folding mandrel toward said path into a position with its folding surface effectively parallel to said path for engagement with a wall portion of a carton blank during its travel therealong, said folding surface contacting said wall portion to simultaneously move the entire length thereof inwardly, and to produce the entire length of the fold therein at one time; D. means along said path for rendering adherent an area of a surface of at least one of the wall portion and of a cooperating portion of the carton blank to be bonded thereto; E. a bonding member having an engagement surface for effecting contact between the wall portion and the cooperating portion of the carton blank; F. means supporting said bonding member in a position along said path downstream of said adherentrendering means for intermittent movement thereof inwardly toward said path to effect said contact of wall and cooperating portions over substantially the entire adherent area thereof at the same time, to effect simultaneous bonding thereat; G. transport means for continuously moving a multiplicity of carton members in rapid succession along said travel path; and H. automatic means driving said transport means, and operating said intermittently moving means and said bonding member support means in timed sequence.
 2. The apparatus of claim 1 wherein said support provides a travel surface adjacent the beginning of said travel path, and wherein said apparatus additionally includes a feed mechanism for the carton blanks comprising a magazine for supporting a stack of carton blanks at an acute angle relative to said travel surface, and with the trailing edge of the bottommost carton blank resting thereupon, means for gripping the bottommost carton blank and pivoting it about its trailing edge to an initial position along said travel path and thereupon effecting the release thereof, said magazine permitting removal of the carton blanks singly therefrom by said gripping means.
 3. The apparatus of claim 2 wherein said gripping means comprises an intermittently evacuable cup having its open end adjacent said magazine, means for intermittently moving said cup into contact with the bottommost carton blank, and means for evacuating said cup to engage a blank thereupon.
 4. The apparatus of claim 2 wherein said feed mechanism additionally includes delivery means comprising a driven transport roller positioned with its circumferential surface projecting upwardly into the plane of said travel surface, and a pressure roller movable to a position over the released carton blank to press it against said circumferential surface of said transport roller and thereby to carry the carton blank from said initial position to said transport means.
 5. The apparatus of claim 2 wherein said feed mechanism additionally includes delivery means comprising a pair of adjacent driven rollers having their axes aligned generally perpendicularly to said travel path to provide a nip therebetween that also extends generally perpendicularly to said path, and means mounting said pair of rollers for intermittent reciprocal movement toward said magazine to a position wherein the released blank is gripped in said nip, and away from said magazine to deliver the blank to said transport means.
 6. The apparatus of claim 1 including at least a second one of said folding mandrels to provide a pair thereof, said folding surfaces of said mandrels being spaced transversely on opposite sides of said travel path and said mandrels being simultaneously movable by said intermittent mandrel moving means toward said path to contact, with said folding surfaces, wall portions along opposite sides of the blank and to produce the entire lengths of the folds therein at one time.
 7. The apparatus of claim 6 including at least a second pair of said folding mandrels spaced from said first-mentioned pair along said travel path.
 8. The apparatus of claim 7 wherein each of said first-mentioned pair of folding mandrels moves inwardly only to an intermediate position toward said path to partially fold the wall portion of the carton blank engaged thereby, and wherein one of said second pair of folding mandrels moves inwardly toward said path from the plane of each of said intermediate positions to fold the same wall portions that were engaged by said first-mentioned pair.
 9. The apparatus of claim 1 wherein said folding surface is substantially equal in length to the wall portion of the carton blank to be engaged thereby, and wherein said apparatus includes a relatively narrow stationary mandrel element that is generally transversely aligned with said folding surface and is mounted inwardly of said travel path and above the upper plane thereof to permit the blank to pass therebetween with portions thereof extending outwardly of said stationary mandrel element, said folding mandrel being mounted on said intermittent moving means for movement from a position downward and outward of said stationary mandrel element to a position upward and inward thereof, whereby movement of said folding mandrel to said upward and inward position folds the wall portion of a carton blank extending outwardly of said stationary element at least partly thereabout.
 10. The apparatus of claim 9 wherein said folding surface is provided by an inwardly projecting elongated ridge that extends parallel to said travel path and cooperates with the remainder of said folding mandrel to form an upper shoulder thereabove and a lower shoulder therebelow, the carton blank riding within said upper shoulder with said folding mandrel in said downward and outward position, and the underside of said ridge bearing against the carton blank wall portion and forcing it about said stationary mandrel element in said upwArd and inward position thereof.
 11. The apparatus of claim 9 wherein said stationary mandrel element has a groove formed therein that extends along said travel path, and wherein said apparatus additionally includes a ram mechanism having an element that is reciprocally movable perpendicularly to said path into and from said groove, said element of said ram mechanism being configured and positioned to simultaneously contact substantially the entire length of a wall portion of the carton blank to fold it about said stationary mandrel element and into said groove to form the entire length of the fold therein at one time.
 12. The apparatus of claim 1 wherein said adherentrendering means is a hot melt adhesive dispenser.
 13. The apparatus of claim 1 wherein at least one of said means moving said folding mandrel and said means supporting said bonding member includes a mounting member supported for continuous rotation about an axis thereof, said mounting member mounting one of said folding mandrel and said bonding member for movement thereof intermittently toward and away from said travel path during different portions of the cycle of rotation of said mounting means.
 14. In a method of forming cartons from carton blanks, the steps comprising: A. continuously moving a multiplicity of carton blanks in rapid succession along a travel path; B. during movement thereof along said path, moving a mandrel intermittently toward said travel path to engage, with a folding surface thereof, each of the blanks at a wall portion defined by a line extending parallel to said path and over substantially the entire length thereof, and folding the entire wall portion inwardly toward said path along said line at the same time; C. rendering adherent an area of a surface of at least one of said wall portion and of a cooperating portion of the carton blank to be bonded thereto; and D. during movement of the carton blank along said path, moving a bonding member intermittently toward said path to effect contact between said wall portion and said cooperating portion of each carton blank over substantially said entire adherent area thereof at the same time, and thereby effecting simultaneous bonding thereat, said movements of carton blanks, mandrel and bonding member occurring in timed sequence.
 15. The method of claim 14 wherein in said step B each of the blanks is engaged over substantially the entire length of wall portions at opposite sides thereof defined by a pair of said lines extending parallel to said path, to simultaneously fold said wall portions in their entirety inwardly toward said path, wherein said surface is rendered adherent by application of an adhesive thereto, and wherein said method additionally includes the steps of: E. automatically feeding a multiplicity of carton blanks in rapid succession to said travel path; and F. during movement of the blanks along said path subsequent to said step B and prior to said step D, engaging each of the blanks over substantially the entire length of second wall portions that are defined by a second pair of lines extending parallel to said path along the opposite sides of each blank inwardly of said first-mentioned pair of lines, and folding the entire second wall portions inwardly toward said path at substantially the same time.
 16. The method of claim 14 wherein said step B is effected in two successive stages.
 17. The method of claim 15 wherein in said automatic feeding step E, each blank is contacted with a member that is continuously moving in one direction, which member is in turn being reciprocated along said travel path toward and from a source of the blanks, superimposition of the movement of the continuously moving member from the source of blanks upon the continuous movement thereof imparting to the blanks a forward speed that is the resultant of the two motion-producing effects.
 18. The method of claim 14 wherein said surface area of said wall portion is renderEd adherent by application of a hot melt adhesive thereto. 